Case Study

Optimizing Steam Systems at The VA Great Lakes Health Care System: A Model for Retro-commissioning and Ongoing Support

SMI Impact

Regulatory Compliance with adherence to VA engineering directives and safety standards, enhancing reliability and safety.

Improved system performance with more reliable heating and sterilization processes across facilities.

Hospital engineering staff are now more knowledgeable and proactive in managing their steam systems.

Significant reductions in steam loss and energy consumption following the steam trap repair program’s implementation.

Background

Steam Management, Inc. (SMI) is engaged by a leading energy service company (ESCO) on an ongoing annual basis to perform critical measurement and verification (M&V) support through the period of performance lifecycle of their energy savings performance contract (ESPC).  This effort includes testing and cataloging the condition and operating status of steam traps at the following hospitals:

  • Jesse Brown VA Medical Center

  • Edward Hines, Jr. VA Hospital

  • Captain James A. Lovell Federal Health Care Center

  • Tomah VA Medical Center

  • Clement J. Zablocki VA Medical Center

This case study examines the implementation of a multi-year comprehensive steam trap testing and repair program aimed at improving energy efficiency, reducing energy waste, enhancing safety, and maintaining compliance with VA engineering standards—including Design Alert 003C2B-DA-151 and VA Directive 1810(1), Amendments 5.a(1) and 5.b(1).

Challenges

The VA Medical Centers were experiencing increased energy costs and inconsistencies in steam system performance, issues that posed risks to both operational reliability and regulatory compliance. The facility's engineering team and the ESCO recognized the need for a systematic approach to steam trap management.

For the ESCO to deliver on its contractual obligation for a 10-year post installation period, the steam trap population between the 5 hospitals must be tested and repaired each year.  There are over 6,000 traps in service between the hospitals and SMI is responsible for testing 33% of the steam traps every calendar year, ensuring full system coverage on a three-year cycle.

Access and scheduling limitations present a challenge as testing must occur during heating season and facility escorts are required to access patient and medical testing/lab areas.  In many cases, controls must be overridden during the testing process to energize steam so that traps can be tested, requiring close coordination with onsite staff.

Annual inspections revealed a high number of malfunctioning steam traps, as well as non-compliance with updated VA engineering standards. These findings highlighted the need not just for one-time fixes, but for a sustainable program focused on compliance, performance, and safety over the life of the ESPC.

Solutions

Data Driven Asset Management

All steam trap testing data is maintained in a shared database that complies with ESCO’s internal asset management system and is accessible by VA facilities staff.  This system allows for year-over-year tracking, enabling the identification of recurring issues, trend analysis, and data-informed decision-making. Traps that fail in consecutive years are flagged to be tested for accuracy.

Coordinated Off-shift Outage Driven Repairs

Repairs are coordinated to minimize disruption to hospital operations. Work is scheduled during the summer and shoulder seasons and in some cases align with annual steam plant shutdowns which occur for one weekend per year. During these periods, SMI crews operate on double shifts to complete high volumes of replacements in short timeframes.

Failed steam traps are replaced with high-quality, durable components that comply with VA standards. This approach to planning and execution ensures maximum uptime, safety, and operational efficiency.

Strict Compliance with VA Standards and Directives

SMI’s work is performed in full adherence to VA specifications, ensuring safe, reliable, and regulation-compliant system operation.

VA design alert 003C2B-DA-151:

Prohibits the use of cast iron fittings and valve housings in high and medium-pressure steam distribution systems to mitigate the risk of failure due to the brittle nature of cast iron, which can lead to catastrophic accidents. This standard directly impacts the selection of replacement components during steam trap repairs.

VA Directive 1810(1) amendments 5.a(1) and 5.b(1):

Mandates that steam system components operating at 15 psig or greater must not include cast iron. The directive directly impacts the selection of steam traps and associated components, including valves, strainers, unions, and fittings, collectively known as the steam trap valve train.

Existing steam traps and associated strainers are primarily made of cast iron, isolation valves and check valves are primarily bronze, and fittings and unions are malleable iron. On steam service 15psi and above, replacement will include cast steel or forged steel steam traps, strainers, unions, and fittings, upgrading safety and longevity across the system.

Conclusion

This multi-site program demonstrates how proactive steam trap management can drive measurable improvements in energy performance, compliance, and patient safety within large healthcare environments. By combining data-driven insights with precision testing and standards-based repairs, SMI and the ESCO have delivered lasting improvements in energy efficiency, system reliability, and VA compliance across critical hospital infrastructure. This program reinforces that effective steam system management is not a one-time fix, but a long-term commitment to ensure lasting reliability and efficiency.

Key Takeaways

Safety is non-negotiable in steam system maintenance

In healthcare facilities, where steam powers critical operations like heating, sterilization, and lab services, even small failures can have serious consequences. The VA's strict regulations on material selection, such as the prohibition of cast iron in pressurized systems, reflect a commitment to protecting patients, staff, and infrastructure.

System efficiency directly impacts reliability and cost

Malfunctioning steam traps not only waste energy but can also compromise the performance of essential hospital functions. Regular testing and timely repairs are essential to minimizing risk and ensuring system uptime.

Documentation drives smarter maintenance

Accurate, centralized records of testing and repairs provide a foundation for trend analysis, compliance reporting, and long-term asset management. A shared database improves visibility across teams and strengthens accountability.

Training empowers proactive facility management

When facility personnel understand how their steam systems operate, they can spot issues sooner, respond more effectively, and maintain peak performance over time.

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